Cost Reduction and Optimization for Manufacturing and Industrial Companies
In today's economic climate, the need to cut costs can be the difference between success and failure. Cost Reduction and Optimization for Manufacturing and Industrial Companies covers all major cost reduction areas, providing easy to read examples and advice on steps to take. It provides the roadmap for implementing recommended actions with true and tried methods by taking a modern, all-inclusive look at manufacturing processes. Based on the author's cost reduction experience gained during 30 years of senior operations and consulting engagements with hundreds of organizations, this book includes easy-to-understand and easy-to-implement cost reduction concepts organized into five general areas --labor, material, design, process, and overhead.
Dives into a cost reduction area and starts with the bottom line first by summarizing key points
Provides proven tactics for cutting costs without a lot of extraneous data
Follows a qualitative and design-oriented approach
Emphasizes quick implementation and measurable cost reduction
Identifies who in the organization should do the work
Outlines risks and suggested risk mitigation actions
Contains numerous tables, graphs, and photos to show the concepts described in the book
Praise for Cost Reduction and Optimization for Manufacturing and Industrial Companies
"In this introductory book, Berk not only takes a modern,
all-inclusive look at manufacturing processes but also provides
substantial coverage of engineering materials and production
systems. It follows a more qualitative and design-oriented approach
than other texts in the market, helping readers gain a better
understanding of important concepts. They'll also discover how
micro-economic conditions relate to the process variables in a
given process as well as how to perform manufacturing science and
quantitative engineering analysis of manufacturing
—Fred Silverman, Director Engineering of Hi-Shear Technology Corporation
"Joe Berk has created a unique, practical and straightforward
approach to cost reduction in manufacturing. This work provides
valuable insights and concrete techniques, based on real-world
experiences, to any manufacturing organization undertaking change
to position itself to compete successfully in the global
—Joe Carleone, President and COO of American Pacific Corporation
Check out author Joseph Berk's blog at http://manufacturingtraining.wordpress.com/
Chapter 1: Organizing a Cost-Reduction Program.
Part I Labor.
Chapter 2: Head Count.
Chapter 3: Time Standards.
Chapter 4: Efficiency.
Chapter 5: Utilization.
Chapter 6: Overtime.
Chapter 7: Multiple Shifts.
Chapter 8: Lost Time.
Chapter 9: The Learning Curve.
Part II Material.
Chapter 10: Make-versus-Buy Determinations.
Chapter 11: Inventory Minimization.
Chapter 12: Material Utilization.
Chapter 13: Minimizing Supplier Costs.
Chapter 14: Supplier Negotiation.
Chapter 15: Supplier Competition.
Part III Process.
Chapter 16: Work-Flow Optimization.
Chapter 17: Setup Time Reduction.
Chapter 18: Material-Handling Improvements.
Chapter 19: Scrap and Rework Reduction.
Chapter 20: Cleanliness.
Part IV Design.
Chapter 21: The Design Approach.
Chapter 22: Requirements Relaxation.
Chapter 23: Tolerance Relaxation.
Chapter 24: Materials Substitution.
Chapter 25: Packaging.
Part V Overhead.
Chapter 26: General Overhead Expenses.
Chapter 27: Travel.
Chapter 28: Inspection.
Part VI Gaining Disciples and Measuring Progress.
Chapter 29: Suggestion Programs.
Chapter 30: Measuring Progress.